Packaging system

ABSTRACT

One embodiment of a packaging system includes a device having a movable component biased to move, in the absence of an external force, from a first position to a second position different from the first position, and a flexible packaging material including an inflated bladder, the inflated bladder removably positioned against the component to hold the component in the first position.

BACKGROUND

Devices, such as imaging devices, namely, printing devices, may include movable components such as an imaging drum and a developer roller. During use these components may be in contact with one another to produce an image on an imaging media. However, it may be desirable that these movable components be out of contact with one another, i.e., alienated, during shipping or storage, so as to reduce or eliminate damage to the components. Accordingly, the components may be shipped separately or may be shipped within separate compartments of a single container. In either case, the device may be reassembled upon initial use, which may require time and expertise of the initial operator. Moreover, additional parts added to the device and utilized to separate the components into separate compartments within a shipping container may be expensive to produce and may add weight to the shipping container, thereby increasing the cost of manufacturing and shipping of the device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of one embodiment of an imaging device in an unpackaged position.

FIG. 2 is a schematic side view of the imaging device of FIG. 1 retained in a shipping position within one embodiment of a packaging system.

FIG. 3 is a schematic side view of another embodiment of an imaging device in an unpackaged position.

FIG. 4 is a schematic side view of the imaging device of FIG. 3 retained in a shipping position within one embodiment of a packaging system.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of one embodiment of a device, such as an imaging device 10, namely, a printing device, in a biased, unpackaged position. The term “biased” may be defined as unrestrained by packaging such that movable components of the device may be biased into an operational position, such as in contact with one another. Similarly, “unbiased” may be defined as restrained by packaging such that movable components of the device are not biased by a biasing element of the device into an operational position.

Imaging device 10 may include a base 12 including a component 14 mounted thereon, such as a developer roller 16. Developer roller 16 may be rotationally mounted on a shaft 18 fixedly secured to base 12. Imaging device 10 may further include a support 20. An imaging component, such as an imaging drum 22, may be rotationally mounted on a shaft 24 fixedly secured to support 20. Shafts 18 and 24 may be parallel to one another such that an external surface 26 of roller 16 may contact an external surface 28 of imaging drum 22 substantially along a line of contact 30 (shown in end view) when imaging device 10 is in a biased, or operational position, as shown in FIG. 1.

Support 20 may be pivotally mounted on base 12 by a shaft 32 at a pivot axis 34. Support 20 may pivot in either of directions 36 and 38 about pivot axis 34. Imaging device 10 may further include a biasing device, such as a spring 40, secured to base 12 and to support 20. Spring 40, in the absence of an external force on imaging device 10, may pivot support 20 in direction 36 to position support 20 in an operational position 42, as shown in FIG. 1. In operational position 42, external surface 26 of roller 16 may contact external surface 28 of imaging drum 22 along line of contact 30 (shown in end view). During operation of imaging device 10, such contact between imaging drum 22 and developer roller 16 may be desirable and may facilitate imaging on an imaging media (not shown) by imaging device 10. However, during periods of non-use, such as periods of shipping or storage of imaging device 10, contact between imaging drum 22 and developer roller 16 may be undesirable and may result in damage to the roller or the drum. In other embodiments it may be desirable to separate or hold together other component groups, such as the imaging drum and a charge roller (not shown), a doctor blade (not shown) and a developer roller, a cleaning blade (not shown) and an imaging drum, and the like. Use of the packaging system to hold components in a shipping and/or storage position may reduce mechanical set, tribo-electric charging, and/or contamination, for example, toner impingement or a chemical reaction due to residual chemicals on a component.

In the embodiment shown, spring 40 is a coil spring and is in a state of compression when imaging drum 22 is in contact with developer roller 16. To separate drum 22 from roller 16, spring 40 must be further compressed. In another embodiment, the biasing member may be positioned on an opposite side of pivot axis 34, i.e., between pivot axis 34 and line of contact 30 of drum 22 and roller 16, such that the biasing member may be in a state of tension when imaging drum 22 is in contact with developer roller 16. In such an embodiment, to separate drum 22 from roller 16, spring 40 would be subjected to an additional tension force. In yet another embodiment, a biasing member may be positioned on each side of pivot axis 34, or a different type of biasing member may be utilized. Moreover, in other embodiments, any type of structure may be utilized to bias movable components of the device into contact during periods of use or operation.

FIG. 2 is a schematic side view of the imaging device 10 of FIG. 1 retained in a shipping position 44 within one embodiment of a packaging system 50. In shipping position 44 the biasing force of spring 40 is overcome by packaging system 50 such that external surface 28 of drum 22 is not in contact with external surface 26 of roller 16. In one example embodiment, packaging system 50 may include a flexible membrane 52 including a first layer 54 and a second layer 56 that define an inflatable air pocket or bladder 58 there between. Bladder 58 may be filled with a liquid or a gas. A gas may be preferable such that in cases of a leak, the imaging device may not be damaged. In certain embodiments, a gas, an inert gas, or mixture of gases, for example, air 60, may be contained within bladder 58 at a pressure greater than atmospheric pressure. In one embodiment, first and second layers 54 and 56 may be transparent, flexible plastic and may be secured together by a heat weld 61 to define bladder 58 there between.

In the embodiment shown, bladder 58 of membrane 52 may be inflated prior to positioning of the membrane on imaging device 10. In such an embodiment, flexible membrane 52 may define a cavity 62 sized to receive an end region 64 of support 20 and an end region 66 of base 12 when spring 40 is compressed such that drum 22 is not in contact with roller 16. In other words, cavity 62 may be sized by the inflation of bladder 58 such that cavity 62 may be positioned around and secure base 12 and support 20 in a shipping or an unbiased position such that spring 40 does not force drum 22 into contact with roller 16.

Cavity 62 may surround a sufficient region of imaging device 10 such that membrane 52 of packaging system 50 may be retained on imaging device 10 by frictional forces between the imaging device 10 and the packaging 50 when the packaging is inflated. Moreover, the packaging system 50 may further be retained on device 10 by spring 40 that may urge end region 64 of support 20 and end region 66 of base 12 against the inner surface 68 of membrane 52. Packaging system 50, therefore, may be referred to as a self-retaining or a self sealing system. In other words, the pressure of the inflated packaging system 50 may define frictional forces sufficient to retain the packaging 50 on the imaging device 10 without utilizing a packaging container, such as a box or a crate (not shown).

When inflated packaging system 50 is utilized, rigid placement structure, such as molded cardboard or expanded foam blocks or end caps (not shown), may not be needed. A packaging box or crate (not shown) may be utilized for ease of stacking packed units and for displaying marketing information, but may not be needed to retain the packaging system in place on imaging device 10 or to retain device components out of contact with one another. The inflated packaging system may define a smaller volume than rigid pre-formed packaging which may allow more units packed with the inflated packaging system to be shipped and/or stored on pallets, thereby decreasing shipping and/or storage costs. The cost of shipping may be further reduced because inflated bladder 58 may define a lesser weight than a weight of molded cardboard or expanded foam blocks or end caps. Upon unpacking packaging system 50, the initial user will have less material to unpack and dispose of than prior packaging systems. Furthermore, packaging system 50 may reduce the need for such molded cardboard or expanded foam blocks or end caps, thereby reducing the cost of manufacturing, materials, and shipping for device 10. After unpacking of device 10 from packaging system 50, bladder 58 may be punctured, further reducing the volume of packing material to be disposed.

In another embodiment, bladder 58 of membrane 52 may be inflated after positioning of the membrane on imaging device 10. In such an embodiment, flexible membrane 52 may initially define a cavity sized to receive end region 64 of support 20 and end region 66 of base 12 when spring 40 forces drum 22 into contact with roller 16. After end regions 64 and 66 of imaging device 10 are positioned within a cavity of membrane 52, bladder 58 may be inflated to reduce the size of the cavity, and so as to provide cavity 62 sized so as to move support 20 and base 12 into an unbiased or shipping position. In other words, cavity 62 may be sized by the inflation of bladder 58, after positioning on imaging device 10, such that cavity 62 may be positioned around and secure base 12 and support 20 in a shipping position such that spring 40 does not force the movable components into contact with one another.

Still referring to FIG. 2, packaging system 50 may further include an inflated bladder 70 that may be positioned between base 12 and support 20, in a region 72 between pivot axis 34 and drum 22 and roller 16. Bladder 70 may be inflated to define a height 74 sufficient to overcome the biasing force of spring 40 so as to separate drum 22 and roller 16. In another embodiment a bladder may be utilized to hold two or more components in contact with one another. Height 74 may be defined by the separation distance of base 12 and support 20 when drum 22 is out of contact with roller 16. Inflated bladder 70 may be self-retained within region 72 by frictional forces on the bladder by base 12 and support 22. Bladder 70 may further be retained within region 72 by the action of spring 40 which may bias base 12 and support 20 against bladder 70, thereby holding the inflated bladder in position.

Upon unpacking of device 10, an initial operator may press end region 64 of support 20 and end region 66 of base 12 together, to allow removal of inflated bladder 70. After removal of bladder 70, the operator may slowly allow the biasing force of spring 40 to bias drum 22 against roller 16, thereby positioning device 10 for use. Thereafter, inflated bladder 70 may be punctured, reducing the volume of packing material to be disposed of. Furthermore, bladder 70 may be less expensive to manufacture than a solid block to be positioned within region 72 and may weigh less than a solid block, such that the manufacturing costs and the shipping costs of packaging system 50 may be reduced when compared to prior shipping systems. Bladder 70 may be inflated to a pressure different than a pressure within bladder 58 such that the two bladders may each exert a different force on the components of device 10, as may be desired for particular applications. Bladder 70 may define an inflated volume different than an inflated volume of bladder 58 such that the bladders may each retain different components in a shipping and/or a storage position.

In other embodiments packaging system 50 may include one of bladders 58 and 70, or may include other inflated bladders that function to retain components of device 10 in a position to prevent damage to the components during shipping. Accordingly, packaging system 50 may generally be described as including at least one inflatable bladder that may retain one or more components of a device in a shipping position, such as retaining components together or holding components apart.

FIG. 3 is a schematic side view of another embodiment of an imaging device 10 in an operational position 42. In this embodiment, imaging device 10 may include imaging drum 22 mounted on support 20. Developer roller 16 may be mounted on a shaft 18 slidably mounted within a track 80. A biasing device, such as a spring 40, may bias shaft 18 in a direction 82 within track 80 to move roller 16 into contact with drum 22 such that device 10 may be ready for operation.

FIG. 4 is a schematic side view of the imaging device 10 of FIG. 3 retained in a shipping position 44 within one embodiment of packaging system 50. In this embodiment, packaging system 50 includes an inflatable bladder 84 positioned between a stop surface 86 of support 20 and movable shaft 18. Bladder 84 may overcome the biasing force of spring 40 to slide shaft 18 in a direction 88 within track 80, so as to position and retain roller 16 out of contact with drum 22. In particular, bladder 84 may define a width 90 sufficient to position and retain shaft 18 in a first end region 92 of track 80. When bladder 84 is removed, shaft 18 may be biased by spring 40 into a second end region 94 (see FIG. 3) of track 80, thereby positioning roller 16 against drum 22 along line of contact 30.

In other embodiments, other components may be positioned in a shipping position by an embodiment of the packaging system. In these other embodiments, in the shipping position the component may be held against another component and upon removal of the packaging system, the component may be allowed to move to a non-contact operational position.

Other variations and modifications of the concepts described herein may be utilized and fall within the scope of the claims below. 

1. A packaging system, comprising: a device including a movable component biased to move, in the absence of an external force, from a first position to a second position different from said first position; and a flexible packaging material including an inflated bladder, said inflated bladder removably positioned against said component to hold said component in said first position.
 2. The system of claim 1 wherein said component is biased by a spring to move from said first position to said second position.
 3. The system of claim 1 wherein said device further includes a second component and wherein in said first position said component is out of contact with said second component and in said second position said component is in contact with said second component.
 4. The system of claim 3 wherein said device comprises an imaging device, said component comprises an imaging drum and said second component comprises a developer roller.
 5. The system of claim 2 wherein said inflated bladder counteracts a biasing force of said spring.
 6. The system of claim 3 wherein said inflated bladder is positioned between said component and said second component.
 7. The system of claim 3 wherein said inflated bladder is positioned around said component and said second component.
 8. The system of claim 1 wherein said packaging material comprises a flexible top sheet of plastic secured to a flexible bottom sheet of plastic and defining said inflated bladder there between.
 9. The system of claim 1 wherein said inflated bladder is filled with at least one gas.
 10. The system of claim 1 wherein said component comprises an elongate member that slides within a track from said first position to said second position, and wherein said inflated bladder holds said elongate member in said first position within said track.
 11. The system of claim 10 further comprising a developer roller secured to a spring and positioned adjacent an imaging drum, said spring secured to and biasing said pin into said second position in the absence of an external force wherein said developer roller contacts said imaging drum when said pin is in said second position, and wherein said inflated bladder holds said pin in said first position within said track so as to hold said developer roller out of contact with said imaging device.
 12. A packaging system, comprising: a structure including a movable part that moves between a biased position and an unbiased position; and a packaging material including a gas filled cushion in contact with and exerting a force against said movable part to retain said movable part in said unbiased position.
 13. The system of claim 12 wherein said movable part moves into said biased position upon removal of said packaging material.
 14. The system of claim 12 wherein said structure includes a toner cartridge and said movable part is chosen from one of an imaging drum and a developer roller.
 15. The system of claim 12 wherein said gas filled cushion is inflated to a pressure of greater than atmospheric pressure.
 16. The system of claim 12 wherein said packaging material at least partially surrounds said structure such that said packaging material is self-secured to said structure in the absence of a packaging container around said packaging material.
 17. A method of packaging a device for shipping, said device including a movable component, the method comprising: inflating a bladder of a flexible packaging material; and securing said flexible packaging material against said device such that said inflated bladder exerts a pressure on said movable component to restrain said movable component.
 18. The method of claim 17 wherein said movable component is biased to move from a first position to a second position, and wherein said securing restrains said movable component in said first position.
 19. The method of claim 17 wherein said device includes a second component, said movable component moves with respect to said second component and wherein said securing comprising positioning said inflated bladder between said movable component and said second component.
 20. The method of claim 17 wherein said device includes a second component, said movable component is pivotally mounted centrally on said second component, and wherein said securing comprising positioning said inflated bladder around at least a portion of said movable component and at least a portion of said second component to pivot and retain said movable component into a stationary position with respect to said second component.
 21. A packaging system, comprising: an imaging device including a movable component biased to move from a first position to a second position; and inflated packing means for retaining said component in said first position.
 22. The system of claim 21 wherein said movable component comprises a developer roller mounted on a pivoting support.
 23. The system of claim 22 wherein said pivoting support is mounted on a base that includes an imaging drum, and wherein when said pivoting support is positioned in said first position said developer roller is out of contact with said imaging drum and in said second position said developer roller is in contact with said imaging drum.
 24. The system of claim 21 wherein said movable component comprises an imaging drum mounted on a pivoting support.
 25. The system of claim 24 wherein said pivoting support is mounted on a base that includes a developer roller, and wherein when said pivoting support is positioned in said first position said imaging drum is out of contact with said developer roller and in said second position said imaging drum is in contact with said developer roller.
 26. The system of claim 21 wherein said inflated packing means is removably positioned on said component.
 27. The system of claim 21 wherein said inflated packing means comprises a flexible sheet including at least one inflated compartment therein.
 28. The system of claim 27 wherein said at least one inflated compartment is deflatable after retaining said component in said first position during shipping.
 29. The system of claim 21 wherein said packing means is self-retaining on said imaging device.
 30. An imaging device, comprising: a flexible membrane including an inflated compartment adapted to exert pressure on a biased cartridge component to retain said component in a shipping position.
 31. The packaging of claim 30 wherein said inflated compartment is sized to be received between a pivoting support and a base.
 32. The packaging of claim 30 wherein said inflated compartment is sized to retain a pin in said shipping position within a track.
 33. A packaging system, comprising: a flexible membrane including a first pocket defining a first inflated volume and a second pocket defining a second inflated volume different from said first inflated volume.
 34. The system of claim 33 wherein said first pocket is inflated to a first pressure and said second pocket is inflated to a second pressure different from said first pressure.
 35. The system of claim 33 wherein said first pocket is sized to retain a first component in an unbiased condition and said second pocket is sized to retain a second component in an unbiased condition.
 36. The system of claim 33 wherein said first pocket defines a cavity adapted to receive a component therein, wherein said first pocket retains said component in an unbiased condition when said component is retained within said cavity.
 37. A packaging system, including: an inflatable bladder that retains a component of a device in a shipping position and prevents movement of said component to an in-use position. 